Electric Motor with Angle Sensor, E.g., Hollow Shaft Encoder

The present invention relates to an electric motor with an angle sensor, e.g., a hollow shaft encoder.

An attachment shaft for connection to an angle sensor which is bonded to a rotor shaft of an electric motor and has a venting spiral groove is described in European Patent Document No. 2 999 094.

A sensor arrangement is described in German Patent Document No. 10 2013 002 049.

An electric motor and an angle sensor are described in German Patent Document No. 10 2019 002 745.

Example embodiments of the present invention provide an electric motor that includes an angle sensor, e.g., a hollow shaft encoder, in which a high-precision but also readily removable connection of an angle sensor to an electric motor is provided.

According to example embodiments, in an electric motor with angle sensor, e. g., hollow shaft encoder, a rotor shaft of the electric motor is connected to an attachment shaft, e. g., connected for conjoint rotation. The attachment shaft has a threaded region, a guide region, a cylindrical portion that effects a centering fit, a second non-circular portion, a connection region, and a first non-circular portion. The rotor shaft has a stepped bore, and the threaded region is screwed into an internally threaded region of the rotor shaft. A thread run-out region adjoins the internally threaded region of the rotor shaft, e.g., on the side of the internally threaded region axially facing away from the guide region. The guide region of the attachment shaft is received with play in the rotor shaft, e.g., with a clearance fit. For example, the cylindrical portion that effects the centering fit has a larger outer diameter than the guide region.

An advantage of this is that the attachment shaft is screw-connected, and with a screw connection actuation is possible without transverse torque, since the first non-circular portion is readily accessible to a tool in the absence of an angle sensor and thus the attachment shaft can be screwed in without transverse force, i.e., with as little central torque as possible. A guide region for pre-centering is provided when the attachment shaft is inserted and when the attachment shaft is screwed further into the threaded bore a centering fit is activated and a stable, resilient connection is achieved through the threaded region. The attachment shaft is thus oriented with high precision to the rotor shaft, i.e., as precisely as possible in alignment with the rotor shaft.

The second non-circular portion provides for ready removing, as a high torque can be applied, which can even destroy an additional adhesive connection. This is because the second non-circular portion is radially much more extended than the first non-circular portion.

Thus, it is only possible to remove a fan that is fitted onto the rotor shaft if the attachment shaft is removed first. However, removing of the attachment shaft is simple and thus readily carried out. The attachment shaft can then be mounted again, but for this the adhesive residue must first be removed and fresh liquid adhesive must be applied to the threaded area and the guide region.

According to example embodiments, the attachment shaft is connected for conjoint rotation with a hollow shaft of the angle sensor. An advantage of this is that the hollow shaft is fitted onto the attachment shaft. A simple force-fit clamping connection is thus possible.

According to example embodiments, a cavity is formed axially between the guide region and the internally threaded region, e. g., to receive adhesive. An advantage of this is that adhesive squeezed out of the guide region or the threaded region when screwing in the attachment shaft can be received.

According to example embodiments, adhesive is arranged between the rotor shaft and the guide region. For example, adhesive escaping from the threaded region or guide region is located in an annular cavity which is delimited radially inwards by the threaded region and radially outwards by the stepped bore of the attachment shaft. An advantage of this is that the attachment shaft connection can be arranged to be as stable and resilient as possible.

According to example embodiments, adhesive is arranged between the internally threaded region and the threaded region. For example adhesive that has escaped from the threaded region is located in the thread run-out region. An advantage of this is that the attachment shaft connection can be arranged to be as stable and resilient as possible.

According to example embodiments, the guide region adjoins the cylindrical portion that effects the centering fit. An advantage of this is that when the attachment shaft is inserted, the guide section takes effect first and only then the centering fit.

According to example embodiments, the second non-circular portion is arranged axially between the cylindrical portion that effects the centering fit and the connection region. An advantage of this is that the second non-circular portion is arranged outside the stepped bore of the attachment shaft, but as close as possible to the adhesive connection.

According to example embodiments, the hollow shaft of the angle sensor is connected to the attachment shaft in the connection region, e.g., in a force-locking manner. An advantage of this is that a simple and highly precise centered connection of the hollow shaft of the angle sensor is possible, and the angle sensor detects the angular position of the hollow shaft in relation to the housing of the angle sensor.

According to example embodiments, an elastic ring, e.g., an O-ring, is arranged between the rotor shaft and the second non-circular portion. For example, the elastic ring is arranged radially outside the cylindrical portion that effects the centering fit. For example, the elastic ring bears against an end face, e. g., an axial end face, of the second non-circular portion facing away from the connection region and/or against an end face, e.g., an axial end face, of the rotor shaft facing the second non-circular portion. For example, the ring axis of the elastic ring is oriented parallel to the axis of rotation of the rotor shaft. An advantage of this is that axial shocks that are transmitted from the motor to the angle sensor are damped by the elastic ring. The elastic ring can also be made from a material such as Teflon, for example. The highest possible proportion of the impact energy is absorbed.

According to example embodiments, the first non-circular portion adjoins the connection region, e.g., on the side of the connection region axially facing away from the second non-circular portion. An advantage of this is that the first non-circular portion forms the axial end region of the attachment shaft and thus a torque can be applied centrally in the middle, i.e., without transverse torque, to screw the attachment shaft into the rotor shaft.

According to example embodiments, a fan is fitted onto the rotor shaft and connected for conjoint rotation with the rotor shaft, and the region covered by the fan in the axial direction overlaps with or includes the region covered by the internally threaded region and/or thread run-out region in the axial direction.

For example, fan blades are formed on the fan that are evenly spaced from one another in the circumferential direction. An advantage of this is that the fan can be removed when the attachment shaft is dismantled from the rotor shaft.

According to example embodiments, the clear inside diameter of the fan or the outside diameter of the rotor shaft in the region covered by the fan in the radial direction is smaller than the largest outside diameter of the second non-circular portion. An advantage of this is that the fan can also be dismantled after dismantling the attachment shaft.

According to example embodiments, the largest outer diameter of the second non-circular portion is larger than the largest outer diameter of the connection region and than the largest outer diameter of the first non-circular portion. An advantage of this is that a high torque can be applied, e.g., for removing the attachment shaft.

According to example embodiments, the first non-circular portion is an outer non-circular portion, e.g., an outer hexagonal portion, or an inner non-circular portion, e.g., an inner hexagonal portion. An advantage of this is that the torque can be introduced into the attachment shaft centrally, i.e., in the middle, e.g., without transverse torque, with a tool, especially when screwing the attachment shaft into the rotor shaft.

According to example embodiments, the second non-circular portion is an outer non-circular portion, e.g., an outer hexagonal portion. An advantage of this is that a simple tool can be used.

According to example embodiments, the first non-circular portion is formed on a screw, which is screwed into a threaded bore, e.g., an axial bore, of the attachment shaft. [[,

For example, a washer or a perforated disk is arranged between the screw head of the screw and the attachment shaft. An advantage of this is that the non-circular portion can be provided by a screw. Thus, it is only necessary to make an axially oriented threaded hole in the attachment shaft and then screw in the screw.

According to example embodiments, the guide region is formed as the jacket surface of a circular cylinder. An advantage of this is that ready and cost-effective production can be implemented.

According to example embodiments, instead of the guide region and the cylindrical region that effects the centering fit, a conically shaped region is formed on the attachment shaft, which region is arranged axially between the threaded region of the attachment shaft and the second non-circular portion. For example, the outer diameter of the conical region increases monotonically, e.g., strictly monotonically, with decreasing distance from the second non-circular portion. An advantage of this is that very precise centering of the attachment shaft to the rotor shaft is possible.

According to example embodiments, the hollow shaft of the angle sensor is connected to the connection region of the attachment shaft in a force-locking manner, and a seal, e.g., a sealing ring such as an O-ring, is arranged between the hollow shaft and the second non-circular portion, which seals the hollow shaft towards the second non-circular portion. For example, the seal is arranged radially outside the connection region, i.e., for example, the radial distance region related to the axis of rotation of the rotor shaft and covered by the seal is at a distance from the radial distance region covered by the connection region and related to the axis of rotation of the shaft. For example, the seal bears against a finely machined end surface of the attachment shaft. For example, the end surface is flat and the normal of the end surface is oriented parallel to the axis of rotation of the rotor shaft. For example, the housing of the angle sensor is connected to a housing part, e.g., a fan hood, of the electric motor by means of a torque support. A shaft seal ring is accommodated in the housing of the angle sensor, which seals towards the hollow shaft, e.g., and a seal lip of the shaft seal ring bears against the radial outer circumference of the hollow shaft. An advantage of this is that the interior space of the angle sensor can be sealed towards the environment.

Further features and aspects of example embodiments of the present invention are explained in more detail with reference to the appended schematic Figures.

1 FIG. 8 11 As illustrated in, the first electric motor has a rotor shaftinto which an attachment shaftis screwed to provide for the attachment of an angle sensor, e. g., a hollow shaft encoder.

11 6 4 4 6 11 3 The rotor shaft has a stepped bore on its axial end region facing the angle sensor, e.g., on its axial end face. The attachment shafthas a threaded region, which is adjoined by a cylindrical guide region. On the side of the cylindrical guide regionaxially facing away from the threaded regiona further cylindrical portion of the attachment shaftadjoins, which portion acts as a centering fit.

8 6 4 9 5 7 6 11 Before being connected to the rotor shaft, the threaded regionand the cylindrical guide regionare coated with adhesive, which can either emerge into a cavityor into a thread run-out, which axially adjoins the threaded regionof the attachment shaft.

8 7 6 11 The stepped bore of the rotor shafthas the thread run-outas the innermost stepped portion, which is arranged axially next to an internal thread into which the threaded regionof the attachment shaftis screwed.

4 11 4 5 9 Axially next to the internal thread, a further stepped portion of the stepped bore is arranged, which receives the guide regionof the attachment shaftwith play, e.g., with a clearance fit. The further stepped portion projects axially beyond the guide region, forming the cavityinto which adhesivecan enter.

11 4 8 The further cylindrical portion of the attachment shafthas a larger diameter than the guide regionand is thus inserted without play, e. g., as a centering fit, into the further stepped portion of the stepped bore of the rotor shaft.

11 8 4 11 11 3 In this manner, when the attachment shaftis inserted into the rotor shaft, guidance is initially achieved by the guide regionand, when the attachment shaftis screwed in further, precise centering is achieved by the further cylindrical portion of the attachment shaft, which portion acts as a centering fit.

11 10 8 For applying a tool, the attachment shafthas a first non-circular portionat its axial end region facing away from the rotor shaft, so that the screwing torque of a tool can be applied centrally in the middle with little or no transverse force.

10 1 FIG. The first non-circular portioncan be arranged as an outer hexagonal region, as illustrated in, or as an inner hexagonal region.

3 1 2 11 2 11 Axially between the region, which acts as a centering fit, and the connection region, a second non-circular portion, e. g., with a width across flats, is formed on the attachment shaft. Thus, a further tool can be applied in this second non-circular portionto provide for removal of the mounting shaftwith such a high torque that the material-locking connection is separated.

11 The attachment shaftcan also be referred to as an adapter shaft.

2 11 8 The largest outer diameter of the second non-circular portionexceeds the largest outer diameters of the regions of the attachment shaftreceived in the rotor shaft.

8 8 2 The inner ring of a roller bearing is fitted onto the rotor shaft, the outer ring of which roller bearing is received in a bearing flange. Axially between this bearing and the second non-circular portion, a fan can be fitted onto the rotor shaftand connected for conjoint rotation with the rotor shaft, e. g., by a feather key connection. The largest outer diameter of the second non-circular portionmay even be larger than the smallest diameter of the fan, e.g., the clear inside diameter of the fan.

11 This is because the fan can be readily replaced by removal of the attachment shaft.

2 3 FIGS.and 10 20 11 21 11 20 21 20 11 20 As illustrated in, instead of the first non-circular portion, a screwcan be screwed into a threaded bore of the adapter shaft, the screw head of which has an outer hexagonal region and/or an inner hexagonal region. An interposed perforated diskprotects the end face of the attachment shaftfacing the screw head of the screw. For example, the perforated diskis arranged between the screw head of the screwand the end face of the attachment shaftfacing the screw head of the screw.

2 4 FIGS.to 23 11 4 3 In addition, as illustrated in, a conical connection regionis provided on the attachment shaftinstead of the cylindrical guide regionand instead of the region acting as a centering fit.

The stepped bore has a corresponding inner cone as a further stepped portion.

This achieves improved guidance and centering.

4 FIG. 40 8 8 45 As illustrated in, a fanis fitted onto the rotor shaft, which is connected for conjoint rotation with the rotor shaftand has fan blades. The airflow generated by the fan is deflected by a fan hood, which is connected to the motor housing of the electric motor, so that the airflow flows along the motor housing.

2 40 The largest outer diameter of the second non-circular portionis larger than the clear inside diameter of the fan.

8 41 42 The rotor shaftis rotatably mounted via the bearingreceived in the bearing shield.

11 2 40 11 The attachment shaftcan be removed using a tool that is attached to the second non-circular portion, so that the fan hood can also be removed and the fancan be replaced after the attachment shafthas been removed.

40 11 40 2 The fancannot be removed without removing the attachment shaft, as the clear inside diameter of the fanis smaller than the largest outside diameter of the second non-circular portion.

1 11 A hollow shaft of the angle sensor is pushed onto the connection regionof the attachment shaftand connected to such region for conjoint rotation.

2 1 2 43 46 Since the second non-circular portionprojects radially beyond the connection region, the hollow shaft can be tightly connected to the second non-circular portionby means of a seal, e.g., a sealing ring, such as an O-ring, and thus the interior of the angle sensor, e. g., the hollow shaft encoder, is sealed off from the environment, since a shaft seal ring received in the housing of the angle sensor including the housing partseals the housing towards the hollow shaft.

46 43 The hollow shaftis arranged in the angle sensor so that it can rotate relative to the housing part.

44 1 8 The sealis arranged radially outside the connection region, e.g., in relation to the axis of rotation of the rotor shaft.

45 The housing of the angle sensor is connected to the fan hoodby a torque support not shown in the Figures.

10 2 For example, instead of the outer hexagonal region or inner hexagonal region a polygonal region can also be used respectively in the first non-circular portionand/or second non-circular portion.

1 Connection region 2 Second non-circular portion, e.g., width across flats 3 Centering fit 4 Cylindrical guide region 5 Cavity 6 Threaded region 7 Thread run-out 8 Rotor shaft 9 Adhesive 10 First non-circular portion, e.g., hexagonal 11 Attachment shaft 20 Screw 21 Perforated disk 22 Inner hexagonal 23 Connection region 40 Fan 41 Bearing 42 Bearing shield 43 Housing of the angle sensor, e.g., hollow shaft encoder 44 Seal 45 Fan hood 46 Hollow shaft